Drive System Design says it has cut electric motor optimization testing time by more than 75% with a new automated eMotor and Inverter Optimization Test Programme aimed at speeding electric propulsion development across automotive, aerospace, marine, defense and off-highway applications.

The company’s platform tackles one of the most time-consuming parts of e-powertrain development: motor optimization mapping, which typically requires heavy engineer supervision and long dyno campaigns. DSD’s new system uses a proprietary MATLAB/Simulink-based automation routine to run four-quadrant Max Torque Per Amp optimization loops and can execute roughly 20,000 test points in under 48 hours.

According to DSD, the setup is designed for continuous unmanned operation and automatically manages thermal conditions while maximizing dyno utilization. The company says that not only shortens testing time, but also produces more repeatable datasets for model correlation and digital twin development. In customer programs, DSD says the approach has reduced optimization testing time by more than 75% compared with typical OEM best-practice processes.

DSD is also adding rig and fixture techniques to replicate real-world wheel or propeller loads earlier in the development cycle, allowing engineers to validate mechanical behavior and durability before integration into vehicles or aircraft. “By combining high-performance test rigs, automation and repeatable engineering methods, we’re helping customers generate the data and confidence they need earlier in the programme,” said Rob Smith, Head of Development & Test.

Source: Drive System Design